WALL OR FLOOR COVERING ELEMENT

Abstract

A covering element including a mineral material and carrying on its front side a polymer-containing decorative layer, the covering element having complementary recesses and projections extending on its side edges, wherein the recesses and projections are formed respectively on side edges facing away from one another, so that the recesses and projections engage into one another when covering elements are adjacent, the recesses and projections being disposed in a carrier plate, the carrier plate comprising mineral elements in a form of flour or particles, wherein the mineral elements comprise gypsum and or cement.

Claims

1. A covering element comprising a mineral material and carrying on its front side a polymer-containing decorative layer, the covering element comprising complementary recesses and projections extending on its side edges, wherein the recesses and projections are formed respectively on side edges facing away from one another, so that the recesses and projections engage into one another when covering elements are adjacent, the recesses and projections being disposed in a carrier plate, the carrier plate comprising mineral elements in a form of flour or particles, wherein the mineral elements comprise gypsum and or cement.

2. The covering element according to claim 1, wherein the carrier plate comprises glass fibers.

3. The covering element according to claim 1, wherein the carrier plate comprises natural fibers.

4. The covering element according to claim 1, wherein the decorative layer comprises a base layer on the carrier plate, wherein on the base layer at least one color pigment-containing digital printing layer is arranged, wherein on the digital printing layer at least one polymer-containing transparent top layer is arranged.

5. The covering element according to claim 4, wherein the polymer-containing transparent top layer has a textured surface.

6. The covering element according to claim 4, wherein the base layer comprises pigments.

7. The covering element according to claim 4, wherein the base layer is transparent.

8. The covering element according to claim 4, wherein the polymer-containing transparent top layer comprises PUR or acrylic.

9. The covering element of claim 4, wherein the polymer-containing transparent top layer comprises a UV-hardening polymer.

10. The covering element of claim 1, wherein the decorative layer comprises a foil, wherein the foil is printed or not printed.

11. The covering element of claim 10, wherein the foil is based on paper or synthetic material, or based on PVC (polyvinyl chloride), PP (polypropylene), PET (polyethylene terephthalate), or polyolefin.

12. The covering element of claim 10, wherein the foil is glued to the carrier plate.

13. The covering element of claim 12, wherein the glue at least partially penetrates into the carrier plate.

14. The covering element of claim 1, wherein the recesses and protrusions are only arranged in the carrier plate and not in the decorative layer.

15. The covering element of claim 1, wherein the carrier plate has an insulating layer on a rear side of the carrier plate.

16. The covering element of claim 15, wherein the insulating layer is an elastomer layer.

17. The covering element of claim 1, wherein the carrier plate is single-layered or multi-layered.

18. A method for producing a covering element, wherein a carrier plate comprising a mineral material is coated with a decorative layer, wherein, before or after application of the decorative layer, recesses and protrusions for a tongue-and-groove connection are generated by milling on side edges of the carrier plate that face away from one another, wherein the carrier plate comprises mineral elements in a form of flour or particles, wherein the mineral elements comprise gypsum and or cement.

19. The method according to claim 18, wherein the carrier plate is coated with at least one base layer which comprises a polymer material, and at least one digital printing layer containing color pigment is applied to the base layer after drying in a digital printing process, and at least one polymer-containing transparent top layer is applied to the digital printing layer at a temperature increased relative to room temperature after drying and or curing, which top layer still at elevated temperature is provided with a surface structure by embossing with at least one structured embossing roll.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The invention is described below by way of example by the schematic drawing, wherein:

[0054] FIG. 1 shows a cross-section through a first covering element, which comprises a decor layer in the digital printing method; and

[0055] FIG. 2 shows a cross-section according to FIG. 2 of a second covering element, which comprises a mineral carrier plate with a mixed layer applied in liquid or solid form.

DETAILED DESCRIPTION

[0056] FIG. 1 shows a plate-shaped covering element 10, which, with other covering elements 10, can be composed in a planar manner to a floor covering, ceiling covering and/or wall covering, for outdoor use as well. The covering element 10 contains a mineral-containing carrier plate 12, which, at its lateral edges 17, 19 facing away from each other, comprises either protrusions 14 or recesses 16, which, with covering elements situated next to each other, form mating tongue/groove connections. So, in covering elements 10 situated next to each other, the protrusions 14 of one covering element 10 engage the recess 16 of the adjacent covering element 10. Optionally, an insulation layer 18 can be arranged on the rear side, underside, respectively, of the carrier plate 12 for footfall sound insulation and/or thermal insulation. This layer preferably is provided directly on the carrier plate 12 or glued thereon.

[0057] On the front side, upper side, respectively, of the carrier plate 12 there is first of all a basic layer 20, which comprises color pigments in order to give the front side, upper side, respectively, of the carrier plate 12 a desired basic color. This basic layer preferably is optional, because basically, with a corresponding choice of the material of the carrier plate 12, the color of the carrier plate can be suitable as a basis for a subsequent digital printing method. A digital print layer 22 is provided on the basic layer 20 in a digital printing method, wherein this digital print layer 22 may be provided not over the entire surface, but only in the areas to be printed. Onto this digital print layer, basic layer 20, respectively, at least one top layer 24 is provided, which in particular consists of a UV-hardening polyurethane or acrylic. A structure 26 is provided on this top layer 24 by an embossing roller, in particular by the hot coating method, which structure preferably reinforces the impression created by the digital print layer 22. In this manner, a covering board is created, which reflects the impression of a desired material very well, for example, a wood layer, a leather layer, a stone layer or a cork layer.

[0058] The top layer 24 can also be formed by a plurality of layers of an in particular UV-hardening polymer. The application of the top layer 24 and the profiling thereof preferably is performed in the hot coating method by means of a hot roller. The hot coating method is known as such.

[0059] FIG. 2 shows an alternative embodiment of a covering element, wherein identical or functionally identical parts in respect to FIG. 1 are provided with the same reference numerals. The floor covering element 30 from FIG. 2 also comprises a carrier plate 12, which is mineral-containing and comprises protrusions 14 and recesses 16 on lateral edges 17,19 facing away from each other. The protrusions and recesses of this tongue/groove system are shown only schematically. In practice, the protrusions 14 and recesses 16 are manufactured as described in document EP 0843763, which document hereby is made subject of the present application. In this context, it should be clarified that a covering element of the invention usually is rectangular, in particular square, and that the recesses and protrusions are formed on four sides, wherein the recesses 16 preferably are arranged on two sides situated next to each other and the protrusions 14 on the other two sides situated next to each other.

[0060] On the rear side or underside thereof, the mineral carrier plate 12 optionally comprises an insulation layer 18, as already known from FIG. 1. This insulation layer is optional and only necessary if a desired footfall sound insulation and/or thermal insulation are desired. Moreover, this insulation layer, if required, can also be applied as a counterbalancing backing layer. On its upper side, the carrier plate 12 comprises a mixed layer 32 of a polymer and a filler. As a filler, for example, leather, cork, wood, stone, mineral powders, sand are suitable, wherein these materials can be provided in the polymer matrix of the mixed layer either as particles or as fibers. The mixed layer preferably is an elastomer layer, which in particular hardens to a modulus of elasticity of 0.05-0.5 GPa, by which it achieves a rubber-like elasticity. In this manner, for example, an impression of cork, wood or leather can be pronounced very well. Such covering element is very suitable as a wall covering element.

[0061] The invention is not limited to the represented exemplary embodiments but can be varied at choice within the scope of protection of the accompanying claims.

REFERENCE NUMERAL LIST

[0062] 10 Wall, ceiling or floor covering element (first embodiment) [0063] 12 mineral carrier plate [0064] 14 protrusiontongue of the tongue/groove connection [0065] 16 recessgroove of the tongue/groove connection [0066] 17 first lateral edge [0067] 18 insulation layer [0068] 19 second lateral edge [0069] 20 basic layerprimercoupling agent [0070] 22 digital printing layer [0071] 24 transparent top layer [0072] 30 wall, ceiling or floor covering element (second embodiment) [0073] 32 mixed layer, in particular applied in liquid form [0074] 34 optionally structured surface, in particular by embossing roller